Stepan UK – Capacity Increase at Stepan’s Chemical Plant


Value: £750,000


Stepan UK is a global manufacturer of specialist intermediate chemicals used in consumer products and industrial applications. It is a leading merchant producer of surfactants.


Stepan wanted to increase the capacity of its UK plant in Stalybridge, Cheshire. The project was to be completed within a strict two week window to avoid impacting Stepan’s production capacity.


Timing and planning were critical to ensure that the work could be carried out within the tight two week timeframe. To ensure that deadlines were met, HFL deployed a team of 16 covering process design, mechanical engineering, piping and layout and control system design. The planning, design and coordination work ran for a period of 6 months prior to the installation phase. One third of the plant was then temporarily shut down while the strip out and installation of new equipment, including the set up of the new control system was carried out. All work was successfully completed within the specified timeframe.


As a result of the upgrade, Stepan has been able to improve quality and has increased its chemical production capacity by 25% enabling it to capture an increased share of the UK surfactant market.

“This project will make a significant contribution to our business success in customer satisfaction, plant operability, safety and reliability.”

European Operations Director, Stepan UK

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Freeman House, Orbital 24
Oldham Street, Denton, Manchester
M34 3SU

Tel: +44 (0) 161 304 5900
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Haden Freeman Limited
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TS10 4RF

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Haden Freeman Limited C/O GEO Group UK Ltd
Charleston Road, Hardley, Hythe
Southampton, Hampshire
SO45 3ZG

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Haden Freeman Limited C/O Madina Group
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